Methods and systems for measurement and inspection of tubular goods

ABSTRACT

Methods and systems for efficient and accurate inspection of tubular goods are disclosed. Inner and outer diameter measurements of a tubular good along the entire length are obtained using laser or other light measurement systems. Discrete sections of a tubular good can be identified. For each section, at least one measurement of an outer diameter of an outside surface of the discrete section, and at least one measurement of an inner diameter of an inside surface of the discrete section are obtained. In addition, a geometric center coordinate for each discrete section of the tubular good is obtained. The measurements defining the outside surface, inside surface, and geometric center in association with the longitudinal position of each discrete section are recorded.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit under 35 U.S.C. §119(e) of U.S.Provisional Application No. 62/361,190, entitled “METHODS AND SYSTEMSFOR ASSESSING TUBULAR GOODS”, filed Jul. 12, 2016, the contents of whichis hereby incorporated by reference herein in its entirety.

BACKGROUND

Full length and circumferential dimensional measurement of tubulargoods, and storage of the numerical results in a data base arraymaintaining an association between each circumferential plane of dataand its longitudinal position, represents the state of the art intubular good inspection systems. A goal of such systems is to use thedata to reconstruct a virtual three-dimensional representation of atubular good, including off-axis deviations along its length. Typicalstate-of-the-art tubular good inspection systems directed to this goalpresently use ultrasonic testing (UT) means to measure wall thicknessdimensions, combined with laser or light emitting apparatus to measurethe associated outer diameters. Those current systems, however, do notcapture off-axis deviations from the baseline longitudinal straightnessof the tubular good.

Such data arrays of wall thickness and associated outer diametermeasurements produce pseudo (virtual) three-dimensional representationsof short (typically one-half inch) sections of a pipe or other tubulargood at discrete longitudinal positions. Each adjacent ring section ischaracterized by its own independent, discrete set of three-dimensionaldata, and the only relative measure between adjacent discrete sectionsis the longitudinal distance between them. When data of this sort isgraphically displayed, with all discrete ring sections connected, aperfectly straight three-dimensional representation of a tubular good isproduced. In other words, the geometric centerlines of the discrete ringsections align themselves along the longitudinal z-axis and do notdeviate radially in the transverse x-y plane.

Manufactured pipes, however, are never perfectly straight and havesections that are radially offset in the transverse x-y plane. When thegeometric centers of each section of a manufactured pipe are measuredand displayed graphically, off-axis hooks (end area deviations), sweeps(full length bows), and helical out-of-straightness patterns are oftenobserved. The tubular good dimensional measurement systems in use todaydo not address the off-axis relational data that is needed to producetrue three-dimensional representations of manufactured pipes, whichexhibit complex off-axis straightness imperfections.

The cost to inspect pipe, for example, with the intent of capturing wallthickness and associated outside diameter dimensions is a function ofseveral factors, including the cost of the measurement apparatus, thecost of the systems used to store and process the generated data arraysfor each pipe, the time required to complete the full inspectionprocess, the manpower and training required to operate the systems, andthe cost to maintain the measurement system and the data storage andprocessing system. Typical retail prices for inspecting a small quantityof pipe range from $900 to $1,200 per joint of oil country tubularcasing. Large quantity retail prices are approximately $300 per joint.With respect to maintenance, ultrasonic inspection facilities with largetransducer arrays are typically employed to measure oil country tubulargoods, which significantly increases maintenance costs. Inspection costscan significantly increase the cost of tubular goods.

In the oil drilling industry, mechanical, multi-arm, spider-like devicesare used to physically measure and log the inside diameters of a tubulargood along its entire length. In other industries, such as the defenseindustry, laser measurement systems are used to measure the insidediameter of a tubular artillery canon barrel along its entire length.Each of these systems is far less expensive than a full lengthultrasonic wall measurement system and can complete a full lengthinspection in a fraction of the time. Each such system, however, is notable to address the drawbacks of conventional systems which do notcapture off-axis deviations from a base line of true straightness or, insome cases, the other remaining tubular dimensions.

FIGURES

Certain features of various non-limiting embodiments according to thepresent disclosure are set forth with particularity in the appendedExamples. The various embodiments, however, both as to organization andmethods of operation, together with advantages thereof, may be betterunderstood by reference to the following description, taken inconjunction with the accompanying drawings as follows:

FIG. 1 is a block diagram of an inspection system in accordance with atleast one embodiment according to the present disclosure;

FIG. 2 illustrates a tubular structure being inspected for outerdiameter and off-axis dimensions using laser or other light emittingdevices and depicts points of direct wall measurement;

FIG. 3 illustrates a tubular structure being inspected for outerdiameter and off-axis dimensions using laser or other light emittingdevices and depicts measurement of wall thickness using single trace UTdevices;

FIG. 4 illustrates a tubular structure being inspected for innerdiameter using laser or other light emitting devices attached to arotary motor mounted on a lance;

FIG. 5 illustrates a tubular structure being inspected for innerdiameter using laser or other light emitting devices attached to arotary motor mounted on a powered trolley car;

FIG. 6 illustrates a tubular structure being inspected for outer andinner diameter using the combined inspection units shown in FIG. 2 andFIG. 4.

FIG. 7 illustrates a tubular structure and corresponding discretesections thereof in accordance with at least one non-limiting embodimentaccording to the present disclosure; and

FIG. 8 illustrates one of the discrete sections shown in FIG. 7.

DESCRIPTION

Numerous specific details are set forth to provide a thoroughunderstanding of the overall structure, function, manufacture, and useof certain embodiments as described in the specification and illustratedin the accompanying drawings. Well-known operations, components, andelements have not been described in detail so as not to obscure theembodiments described in the specification. The reader will understandthat the embodiments described and illustrated herein are non-limitingexamples, and thus it can be appreciated that the specific structuraland functional details disclosed herein may be representative andillustrative. Variations and changes thereto may be made withoutdeparting from the scope of the Examples.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”), and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a system,device, or apparatus that “comprises,” “has,” “includes,” or “contains”one or more elements possesses those one or more elements, but is notlimited to possessing only those one or more elements. Likewise, anelement of a system, device, or apparatus that “comprises,” “has,”“includes,” or “contains” one or more features possesses those one ormore features, but is not limited to possessing only those one or morefeatures.

Various non-limiting methods and systems for efficient inspection oftubular goods are disclosed herein. In at least one aspect, wallthickness measurements of a tubular good along an entire length andcircumference of the tubular good are obtained by calculations involvingthe outside and inside diameter dimensions which are measured by laseror other light measurement systems. Discrete ring-shaped sections of atubular good can be identified. For each such discrete section, at leastone measurement of an outer diameter of an outside surface of thediscrete section, and at least one measurement of an inner diameter ofan inside surface of the discrete section are obtained. In addition, ageometric center coordinate for each discrete section of the tubulargood is obtained. The measurements defining the outside surface, insidesurface, and geometric center in association with the longitudinalposition of each discrete section are recorded.

Each measurement of the outer and inner diameters and associatedgeometric center can represent a small fraction of the total respectivediameters and geometric centers of the tubular good in three-dimensionalspace. A number of such measurements can be utilized to create a virtualthree-dimensional form of the tubular good including straightnessanomalies, whether longitudinal or helical in nature.

In at least one aspect, the outer diameters, inner diameters, and/orgeometric centers of the discrete sections of the tubular good can bevisually represented or displayed so that anomalies of interest,including straightness anomalies, for example, may be readily detected.In one example, the outer diameters, inner diameters, and/or geometriccenters of the discrete sections can be graphically represented. In oneexample, different shades or colors may represent different values ofthe outer diameters, inner diameters, and/or geometric centers of thediscrete sections. For example, a darker shade can represent a greaterinner diameter and a lighter shade may represent a smaller innerdiameter.

In at least one possible aspect, the recorded values of the outerdiameters, inner diameters, and/or geometric centers of the discretesections of the tubular good may be processed to obtain a virtual wallthickness of the tubular good along its length and/or predict effects ofstressors on the tubular good such as, for example, stressors that maybe encountered when the tubular good is in service.

In at least one aspect, the present disclosure relates tonon-destructive measurement of tubular goods. For example, in at leastone aspect, non-destructive methods and systems are used to determineoutside diameters, inside diameters, geometric centers, and/or wallthicknesses of steel pipe or other tubular goods by use of laser orother light measurement apparatus. In at least one aspect, the presentdisclosure relates to an improved method of collecting, storing,displaying, and otherwise utilizing information derived from laser orother light measurement systems to capture dimensional data andcalculate and store wall thickness data for a tubular good. In at leastone aspect, the present disclosure relates to the use of laser or otherlight measurement systems to acquire incremental data representingsmall, discrete sections of the outside and inside tubular surfaces inassociation with three-dimensional positional data pertaining to eachsmall, discrete section, so that the wall of a tubular, orsubstantiality tubular, structure, or portions thereof, can bedisplayed, imaged, examined, and/or utilized in simulative/comparativeprograms as a three-dimensional object.

In various instances, a method for generating a virtualthree-dimensional profile of a tubular, or at least substantiallytubular, structure, or region(s) thereof, includes selecting diametricsections of the tubular structure at discrete positions along apredetermined length of the tubular structure. In one aspect, thepredetermined length can be the entire length of the tubular structure.The method further includes determining, for each section, a pluralityof outer diameters of an outside surface of the section, and a pluralityof inner diameters of an inside surface of the section. The number ofinner diameters and outer diameters measured represents a desiredresolution of the selected section. The method further includesdetermining a geometric center coordinate for each of the sections. Themethod further includes employing the determined inner diameters, outerdiameters, and corresponding geometric center coordinates to create avirtual three-dimensional profile of the tubular good including, forexample, surface anomalies.

Referring to FIG. 1, an inspection system 4 for inspecting a tubularstructure 8 is depicted. The tubular structure 8 can, for example, be anoil country tubular good such as a pipe, as illustrated in FIGS. 2-6.The system 4 includes a circuit 10. The circuit 10 includes a controller12, an outer unit 14, a middle unit 15, and an inner unit 16. Thecontroller 12 may comprise one or more processors 18 (e.g.,microprocessor, microcontroller) coupled to at least one memory circuit20. At least one memory circuit 20 stores machine executableinstructions that, when executed by the processor 18, cause theprocessor 18 to perform one or more functions. In one aspect, the atleast one memory circuit 20 stores machine executable instructions that,when executed by the processor 18, cause the processor 18 to generate avirtual three-dimensional profile of a tubular structure 8 based oninput data from the inner unit 16, the middle unit 15, and the outerunit 14.

The steps performed by the processor 18 may include selecting discretediametric sections of the tubular structure 8 at discrete positionsalong a predetermined length of the tubular structure 8. In one aspect,the predetermined length can be the entire length of the tubularstructure 8 or a portion thereof. The steps performed by the processor18 may further include determining, for each diametric section, aplurality of outer diameters of an outside surface of the section, and aplurality of inner diameters of an inside surface of the section. Thenumber of inner diameters and outer diameters determined for a discretesection represent a desired resolution of the selected section. Thesteps performed by the processor 18 may further include determininggeometric center coordinates for each of the sections and using wallmeasurements provided by the middle unit 15 to calibrate the orientationand position of the outer diameters with respect to the inner diametersand to correct for any errors of frictional slippage of the tubularstructure 8 as it moves through the outer unit 14, middle unit 15, andinner unit 16. The method further includes employing the determinedinner diameters, outer diameters, and corresponding geometric centercoordinates of the multiple analyzed sections of the tubular structure 8to create a virtual three-dimensional profile of the tubular structure8.

In various instances, one or more of the various steps described hereincan be performed by a finite state machine comprising either acombinational logic circuit or a sequential logic circuit, whereineither the combinational logic circuit or the sequential logic circuitis coupled to at least one memory circuit. At least one memory circuitstores a current state of the finite state machine. The combinational orsequential logic circuit is configured to cause the finite state machineto perform the steps. The sequential logic circuit may be synchronous orasynchronous. In other instances, one or more of the various stepsdescribed herein can be performed by a circuit that includes acombination of the processor 18 and the finite state machine, forexample.

The controller 12 and/or other controllers of the present disclosure maybe implemented using integrated and/or discrete hardware elements,software elements, and/or a combination of both. Examples of integratedhardware elements may include processors, microprocessors,microcontrollers, integrated circuits, ASICs, PLDs, DSPs, FPGAs, logicgates, registers, semiconductor devices, chips, microchips, chip sets,microcontrollers, SoC, and/or SIP. Examples of discrete hardwareelements may include circuits and/or circuit elements such as logicgates, field effect transistors, bipolar transistors, resistors,capacitors, inductors, and/or relays. In certain instances, thecontroller 12 may include a hybrid circuit comprising discrete andintegrated circuit elements or components on one or more substrates, forexample.

The processor 18 may be any one of a number of single or multi-coreprocessors known in the art. The memory circuit 20 may comprise volatileand non-volatile storage media. In one embodiment, the processor 18 mayinclude an instruction processing unit and an arithmetic unit. Theinstruction processing unit may be configured to receive instructionsfrom memory circuit 20.

Referring to FIGS. 2-3, the outer unit 14 includes a rotatable drum 22which can be configured to rotate about a longitudinal axis 24. Therotatable drum 22 may have a cylindrical shape and a fixed outer shell23, as illustrated in FIGS. 2-3. One or more laser units can bepositioned on an inner wall of the rotatable drum 22. In at least oneexample, laser units 26, 26′ are disposed on opposite sides of an innerwall or face of the rotatable drum 22. The laser units 26 and 26′ arecircumferentially disposed on the inner wall or face of the rotatabledrum 22 at angles of 90° and 270°. Said another way, the laser units 26,26′, as a set, may be circumferentially spaced apart by about 180° onthe inner wall or face of the rotatable drum 22. The laser units 26 and26′ may be oriented toward one another. Additional sets of lasermeasurement units may be disposed on the inner wall or face of therotatable drum 22 spaced apart by approximately 180°.

In at least one aspect, the laser units 26, 26′ are configured tocommunicate input data to the controller 12 based on measurements takenby the laser units 26, 26′ and additional sets of laser units, ifpresent. The controller 12 may employ the input data from the laserunits 26, 26′ to determine outer diameter values of the outside surfaceof tubular structure 8 that are based on the measurements. In certaininstances, the measurements comprise gap distances that aresimultaneously measured between the laser units 26, 26′ and the outsidesurface of the tubular structure 8 as the tubular structure passesthrough the rotatable drum 22. The same can be said of any additionalsets of non-interfering laser units that may be employed on the innerwall or face of the rotatable drum 22.

Referring to FIG. 4, the inner unit 16 includes a mounting member 28 inthe form of a stationary mandrel, for example, extending along thelongitudinal axis 24. Two laser units 30, 30′ are affixed to arotational motor 17 which is attached to and extends from the mountingmember 28. In the arrangement illustrated in FIG. 4, the laser units 30,30′ are pointing in opposite directions along an axis 32 that isperpendicular, or at least substantially perpendicular, to thelongitudinal axis, and the laser units 30 and 30′ are rotating about thelongitudinal axis 24. Additional sets of laser measurement units may beaffixed to the rotational motor 17 at approximately 180° apart. Inanother embodiment, as illustrated in FIG. 5, an inner unit 16′ canutilize a power driven trolley car 43 that pulls itself and anyconnecting cables 44 through the interior of the tubular structure 8. Inthis embodiment the laser units 30, 30′ are connected to a rotary motor17 which in turn is attached to the front of trolley car 43. Additionalsets of laser measurement units 30, 30′ may be affixed to the rotationalmotor 17 at approximately 180° apart.

Although outer unit 14 and inner unit 16 can be operated at differentstations, in at least one embodiment, illustrated in FIG. 6, the outerunit 14 and the inner unit 16 operate at the same station such that thelaser units 26, 26′, 30, 30′ are aligned with one another along the axis32. In at least one instance, the mounting member 28 is configured to becentered on the inside of the tubular structure 8 with centering guideflukes or rollers that make contact with the inside wall of the tubularstructure 8.

Like the laser units 26, 26′, the laser units 30, 30′ are configured tocommunicate input data to the controller 12 based on measurements takenby the laser units 30, 30′. The controller 12 may employ the input datafrom the laser units 30, 30′ to determine inner diameter values of theinside surface of the tubular structure 8 that are based on themeasurements taken by the laser units 30, 30′. In certain instances, themeasurements comprise gap distances that are simultaneously measuredbetween the laser units 30, 30′ and the inside surface of the tubularstructure 8.

In operation, a tubular structure 8 is centered around the longitudinalaxis 24, as illustrated in FIG. 6. The tubular structure 8 is translatedalong the longitudinal axis 24 toward the inner unit 16 and outer unit14 at separate operating stations as illustrated in FIGS. 2-5 or in somecombined operating station such as illustrated in FIG. 6. In each ofthese cases the tubular structure 8 is translated so as to pass betweenthe inner unit 16 and/or outer unit 14. In other words, the tubularstructure 8 is configured to move through the outer unit 14 and aroundthe inner unit 16 at separate operating stations or in a single combinedstation. As the tubular structure 8 is translated axially with respectto the outer unit 14 and inner unit 16, the laser units 26, 26′, 30, 30′continuously take their respective measurements of the outside andinside surfaces of the tubular structure 8.

In order to calibrate the measurement data of the outer unit 14 andinner unit 16 in order to adjust for any frictional slippage along thelength or rotational slippage about the circumferential direction, themiddle unit 15 provides at least two direct wall measurements atapproximately 90° apart and at each end of the tubular structure 8including the longitudinal separation distance 27, as illustrated inFIGS. 2, 5, and 6. In another embodiment, and as illustrated in FIG. 3,the middle unit 15 provides continuous or intermittent wall measurementsin two or more lines at approximately 90° apart along the length of thetubular structure 8 as it advances through the outer unit 14. In thisembodiment at least two single trace wall measurement devices such as,for example, ultrasonic testing (UT) transducers or other suitable wallsensors are employed. The wall measurement data provided by the middleunit 15 is also used to synchronize the outer diameter and innerdiameter data provided by outer unit 14 and inner unit 16 such that asuitably accurate three dimensional relationship of the tubularstructure 8 is established and can result in the output of a virtualthree-dimensional display or data base of the tubular structure 8 byprocessor 18.

The user input device 6 can also be employed to enter identificationinformation corresponding to the particular tubular structure 8 to beinspected by the inspection system 4, for example. Other information canalso be entered such as, for example, length calibration data, otherspecial calibration data, and the date and time of the inspection. Theentered information can be stored in a storage medium such as, forexample, the memory circuit 20.

In an alternative embodiment, the inner unit 16 and outer unit 14 can belongitudinally transitioned toward the tubular structure 8 while thetubular structure 8 remains stationary. In such embodiment, the mountingmember 28 is configured to longitudinally advance the laser units 30,30′ through the tubular structure 8. In addition, the rotatable drum 22is configured to longitudinally advance the laser units 26, 26′ as theyrotate around the tubular structure 8.

Referring again to FIGS. 2-4 and 6, laser units 26, 26′, 30, 30′ areconfigured to rotate about the longitudinal axis 24 as the tubularstructure 8 is advanced along the longitudinal axis 24 with respect toouter unit 14 and inner unit 16. The laser units 26, 26′, 30, 30′can beconfigured to rotate about the longitudinal axis 24 at the same, or atleast substantially the same, rotational speed and rotational direction.Alternatively, laser units 26, 26′, 30, 30′ can be configured to rotateabout the longitudinal axis 24 at different rotational speeds and/or indifferent rotational directions. During rotation, the laser units 26,26′, 30, 30′ continuously take their respective measurements of theoutside and inside surfaces of the tubular structure 8.

The speed of rotation of the laser units 26, 26′, 30, 30′can also affectthe resolution of the virtual three-dimensional profile of the tubularstructure 8 that is generated by the controller 12. The greater thespeed of the tubular structure 8 relative to the inner unit 16 and outerunit 14, the smaller the number of inner and outer diameters determinedby the controller 12 for a defined length of the tubular structure 8. Incertain instances, as illustrated in FIG. 1, the circuit 10 includes auser input device 6 which can be used to select a speed of movement ofthe tubular structure 8 through the inner unit 14 and outer unit 16corresponding to a desired resolution of the virtual three-dimensionalprofile of the tubular structure 8. The limiting resolution regardlessof traverse speed of tubular structure 8 and the rotational speed of thediameter sensing devices is the maximum electronic repetitive responsespeed of the overall inspection system 4.

In various embodiments, the outer unit 14 is axially fixed. The laserunits 26, 26′ obtain their measurements as the tubular structure 8 istranslated through the outer unit 14. In addition, the laser units 30,30′ may obtain their measurements as the inner unit 16 progresses withinand through the tubular structure 8. Translational and rotationalmovement of the laser units 30, 30′ are tracked by the controller 12.

Referring to FIG. 7, a tubular structure 8, or at least a portionthereof, is divided into a number of discrete sequential cross-sectionsor rings 46 for a desired resolution. The sections or rings 46 can bedefined in a plane orthogonal to the longitudinal axis 24. For each ring“j”, as illustrated in FIG. 8, an outside surface profile of the ring“j” is plotted based on coordinates (X_(ij) ^(OD), Y_(ij) ^(OD), Z_(j)^(OD)) in a fixed global coordinate system. In addition, an insidesurface profile of the ring “j” is plotted based on coordinates (x_(ij)^(ID), y_(ij) ^(ID), z_(j) ^(ID)) in a local coordinate systemassociated with the inner unit 16. If there are M measurements (rings)along a central axis of the tubular structure 8, and N measurementsalong the circumferential direction, each one of the outside and insidesurfaces is represented by a number of measurements that is equal to thevalue N multiplied by the value M. The three-dimensional measurementsare presented in a fixed global coordinate system, denoted as (X_(ij)^(OD), Y_(ij) ^(OD), Z_(j) ^(OD)) and (X_(ij) ^(ID), Y_(ij) ^(ID), Z_(j)^(ID)) for outside and inside surfaces, respectively, in which i is from1 to N for the circumferential direction, and j is from 1 to M for theaxial direction.

For each ring “j”, a geometric center of the outside surface can bedetermined based on the equation:

$\left\{ {\begin{matrix}{X_{Cj}^{OD} = {\frac{1}{N}{\sum\limits_{i = 1}^{N}X_{ij}^{OD}}}} \\{Y_{Cj}^{OD} = {\frac{1}{N}{\sum\limits_{i = 1}^{N}Y_{ij}^{OD}}}} \\{Z_{Cj}^{OD} = Z_{j}^{OD}}\end{matrix}.} \right.$

Similarly, a geometric center of the inside surface for each ring “j”can be determined based on the equation:

$\left\{ {\begin{matrix}{X_{Cj}^{ID} = {\frac{1}{N}{\sum\limits_{i = 1}^{N}X_{ij}^{ID}}}} \\{Y_{Cj}^{ID} = {\frac{1}{N}{\sum\limits_{i = 1}^{N}Y_{ij}^{ID}}}} \\{Z_{Cj}^{ID} = Z_{j}^{ID}}\end{matrix}.} \right.$

Coordinates of the centerlines of the inside and outside surfaces canthen be used to determine the straightness of the tubular structure 8.For an outside surface, coordinates of the centerlines are:

(X _(Cj) ^(OD) , Y _(Cj) ^(OD) , Z _(j) ^(OD)), J=1, . . . , M.

For an inside surface, coordinates of the centerlines are:

(X _(Cj) ^(ID) , Y _(Cj) ^(ID) , Z _(j) ^(ID)), J=1, . . . , M.

In various instances, the input data from the laser units 26, 26′, 30,30′ are presented in a local coordinate system for each of the insiderand outside surfaces. To process the input data, a transformation fromthe local coordinate system to a fixed global coordinate system isimplemented. The transformation can be performed for input datacorresponding to the outside and inside surfaces. Once the input datafor the outside and inside surfaces are presented in a single globalcoordinate system, all the geometric properties (e.g., center of circle,diameters, ovality, wall eccentricity, pipe straightness, etc.) can thenbe calculated accordingly.

For either an outside or inside surface, input data can be presented ina local coordinate system, attached to the laser unit taking themeasurements, as:

$x = {\begin{pmatrix}x \\y \\z\end{pmatrix}.}$

Through a coordinate transformation (including rotation andtranslation), the local coordinates can then be presented in a fixedglobal coordinate system for data points of both of the outer and innersurfaces using the equation:

X=Rx+T,

wherein global coordinates

${X = \begin{pmatrix}X \\Y \\Z\end{pmatrix}},$

translation vector

${T = \begin{pmatrix}X_{0} \\Y_{0} \\Z_{0}\end{pmatrix}},$

and rotation

matrix:

$R = {{R_{Z}R_{Y}R_{X}} = {\quad{{{\begin{bmatrix}{\cos \; \theta_{Z}} & {{- \sin}\; \theta_{Z}} & 0 \\{\sin \; \theta_{Z}} & {\cos \; \theta_{Z}} & 0 \\0 & 0 & 1\end{bmatrix}\begin{bmatrix}{\cos \; \theta_{Y}} & 0 & {\sin \; \theta_{Y}} \\0 & 1 & 0 \\{{- \sin}\; \theta_{Y}} & 0 & {\cos \; \theta_{Y}}\end{bmatrix}}\begin{bmatrix}1 & 0 & 0 \\0 & {\cos \; \theta_{X}} & {{- \sin}\; \theta_{X}} \\0 & {\sin \; \theta_{X}} & {\cos \; \theta_{X}}\end{bmatrix}},}}}$

and wherein θ_(Z) is the angle of rotation about the global Z-axis,θ_(Y) is the angle of rotation about the global Y-axis, and θ_(X) is theangle of rotation about the global X-axis.

In various instances, collapse and other performance properties of thetubular structure 8 for each discrete cross-sectional ring along thefull length of the tubular structure 8 can be calculated. Also, entirethree-dimensional data can be utilized for three-dimensional modeling toaccurately predict collapse strength and other performance properties ofa specific tubular structure 8.

Once the three-dimensional coordinates of the outer and inner surfacesof a tubular structure 8 are obtained and stored in a computer storagesystem, coordinates defining the centers of any discrete section canthen be calculated. In general, and with reference to FIG. 7, thethree-dimensional coordinates of the centers of all the discretesections of the entire length of a tubular good form three-dimensionallines and curves 45. By using the method of least squares, one cancalculate a reference base line of straightness of the particulartubular structure or portions thereof. In the tubular industry, there isno unique means to define the base reference line for the straightnesscalculation. The end user may specify the methodology of theirpreference. Two common scenarios are provided in the American PetroleumInstitute (API) Specification 5CT: measurements of full-lengthstraightness (sweep) and end straightness (hook) of a 5-foot end sectionon both ends of the said tubular. Utilizing the system described herein,not only can the above two common scenarios be evaluated moreaccurately, but also the full-length three-dimensional shape (such ashelical curve) and/or the local bows along the entire length of thetubular good can be measured and visually displayed, and deviations froma reference base line can be provided by digital or graphical output.

Referring to FIG. 3, single trace wall thickness measuring instruments40 can be incorporated into the inspection system 4 for calibrationpurposes to ensure that the inside surface profile or shell is placedproperly within the outside surface profile or shell. In at least oneaspect, two traces, placed outside the rotating drum 22 andapproximately 90° apart, are sufficient to lock the inside and outsidesurface profiles together. Alternatively, the single trace instruments40 could be positioned in the interior of the rotating drum 22. Examplesof suitable single trace instruments 40 include non-overlapping singletrace ultrasonic testing (UT), laser-UT, gamma-ray, magnetic and otherwall sensing devices. In an alternative embodiment, the single traceinstruments 40 could be substituted or used in conjunction with at leastfour direct wall measurement points 42, two or more at each end of thetubular structure 8 including the longitudinal separation distance 27,as illustrated in FIGS. 2, 5, and 6. In other embodiments, advancedpositioning devices, such as a separate straightness reference laserbeam or a multi-dimensional gyroscope, can be used to determine theoff-axis dimensions with respect to the geometrical center coordinatesrepresenting discrete longitudinal sections associated with the outsidesurface or inside surface circumferential measurements.

EXAMPLES

The following examples describe aspects of several non-limitingembodiments of methods and systems according to the present disclosure.

Example 1

A method of inspecting a tubular good comprises selecting across-section of the tubular good that is transverse to a longitudinalaxis extending through the tubular good; longitudinally positioning atleast one measuring apparatus at a position with respect to thecross-section; while the measuring apparatus is at the position,determining the longitudinal position of the measuring apparatus alongthe longitudinal axis of the tubular good; while the measuring apparatusis at the position, determining the circumferential position of themeasuring apparatus about a circumference of the cross-section;selecting diametric sections in discrete positions around thecircumference of the cross-section of the tubular good; measuring anoutside diameter and inside diameter at each of the diametric sectionsaround the circumference of the cross-section via the at least onemeasuring device; determining a geometric center of the cross-section;and repeating the above-listed steps at a plurality of other sections ofthe tubular good that are orthogonal to the longitudinal axis.

Example 2

The method of Example 1, wherein the measuring device comprises a lasermeasuring device.

Example 3

The method of Example 1, wherein the measuring device comprises a lightmeasuring device.

Example 4

The method of Example 1, further comprising the step of storing digitalrecordings of the outer diameters, the inner diameters, and thegeometric center of the cross-section.

Example 5

The method of Example 4, wherein the digital recordings comprises firstdigital recordings configured to define an outer surface of the tubulargood, and second digital recordings configured to define an innersurface of the tubular good.

Example 6

The method of on or more of Examples 1-5, further comprising the step ofassociating the outer surface and the inner surface of the tubular goodto calculate a wall of the tubular good in three dimensional space.

Example 7

The method of one or more of Examples 1-6, further comprising the stepsof: measuring the relative position and distance of an outer surfacegeometric center point of an initial section from an inner surfacegeometric center point of the initial section; and measuring therelative position and distance of an outer surface geometric centerpoint of a last section from the inner surface geometric center point ofthe last section.

Example 8

The method of one or more of Examples 4-8, further comprising the stepof using at least some of the digital recordings to compute the effectof stressors on the calculated wall of the tubular good.

Example 10

The method of Example 1, wherein the discrete positions of the diametricsections are equally spaced around the circumference.

Example 11

A system of inspecting a tubular good, the system comprising: an outerunit comprising at least one outer measuring device; an inner unitcomprising at least one inner measuring device; and a control circuitcoupled to the outer unit and the inner unit, wherein the controlcircuit is configured to perform the steps of: selecting a cross-sectionof the tubular good that transects a longitudinal axis extending throughthe tubular good; longitudinally positioning the outer unit at a firstposition outside the cross-section; while the outer unit is at the firstposition, determining the longitudinal position of the outer unit alongthe longitudinal axis of the tubular good; while the outer unit is atthe first position, determining the circumferential position of theouter unit about a circumference of the cross-section; longitudinallypositioning the inner unit at a second position inside thecross-section; while the inner unit is at the second position,determining the longitudinal position of the inner unit along thelongitudinal axis of the tubular good; while the inner unit is at thesecond position, determining the circumferential position of the innerunit about the circumference of the cross-section; selecting diametricsections in discrete positions around the circumference of thecross-section of the tubular good; measuring an outside diameter andinside diameter at each of the diametric sections around thecircumference of the cross-section via the at least one measuringdevice; determining a geometric center of the cross-section; andrepeating the above-listed steps at a plurality of other sections of thetubular good that are orthogonal to the longitudinal axis.

Example 12

The system of Example 11, wherein the outer unit comprises a lasermeasuring device.

Example 13

The system of Example 12, wherein the inner unit comprises a lasermeasuring device.

Example 14

The system of Example 11, wherein the outer unit comprises a lightmeasuring device.

Example 15

The system of Example 14, wherein the inner unit comprises a lightmeasuring device.

Example 16

The system of Example 11, wherein the control circuit comprises amemory, and wherein the control circuit is configured to store digitalrecordings of the outer diameters, the inner diameters, and thegeometric center of the cross-section in the memory.

Example 17

The system of Example 16, wherein the digital recordings comprise: firstdigital recordings configured to define an outer surface of the tubulargood; and second digital recordings configured to define an innersurface of the tubular good.

Example 18

The system of one or more of Examples 11-17, further comprising the stepof associating the outer surface and the inner surface of the tubulargood to calculate a wall of the tubular good in three dimensional space.

Example 19

The system of one or more of Examples 11-18, further comprising a middleunit, wherein the control circuit utilizes the middle unit to performthe steps of: measuring the relative position and distance of an outersurface geometric center point of an initial section from an innersurface geometric center point of the initial section; and measuring therelative position and distance of an outer surface geometric centerpoint of a last section from the inner surface geometric center point ofthe last section.

Example 20

The system of one or more of Examples 14-20, wherein the control circuitis configured to construct a virtual three-dimensional form of thetubular good using at least some of the digital recordings stored in thememory.

Example 21

A method for collection and storage of information representing theouter and inner diameters of a tubular surface, and the associatedgeometrical centers of the longitudinal section which represent thethree-dimensional longitudinal or helical straightness of tubular goods,the method comprising: (a) selecting a diametric section of thecircumference of the tubular good about which information representingthe outer diameter, inner diameter, and geometric center of thelongitudinal section is to be recorded in a format readable by digitalcomputer means; (b) determining number and spacing of diametric sectionsin discrete positions around the circumference of a longitudinal sectionof the tubular good which will produce information representingcircumferential outside and inside diameters of the tubular good havinga determined resolution and a geometric center representing theassociated longitudinal section; (c) longitudinally positioning a laseror light measuring apparatus which is capable of measuring the outsidediameter and inside diameter at a desired number of adjacent positionsaround the circumference and measuring the geometric center of eachassociated longitudinal section of the tubular good in a plurality ofadjacent positions in an area of the tubular good to be inspected; (d)while the laser or light measuring apparatus is at the position,determining the longitudinal position of the laser or light measuringapparatus along the axis of the tubular good; (e) while the laser orlight measuring apparatus is at the position, determining thecircumferential position of the laser or light measuring apparatus aboutthe circumference of the tubular good; (f) while the laser or lightmeasuring apparatus is at the position, causing the laser or lightmeasuring apparatus to determine the outer and inner diameters, andgeometric center of a discrete longitudinal section of the tubular goodto which the laser or light measuring apparatus is proximate; (g) makinga digital recording of outer and inner diameters, geometric center ofthe section, the longitudinal position, and the circumferential positionin an associated relationship; (h) repeating steps (c) through (g) aboveat a plurality of other circumferential and longitudinal positions ofthe selected section which have not been previously determined andrecorded, until all of the outside and inside diameters representing thedetermined resolution of the selected section has been determined andrecorded, and is represented by a plurality of recordings, each of whichrepresents outer and inner diameter, the outer and inner geometriccenters of the section, longitudinal position and circumferentialposition of a discrete portion of the calculated wall of the tubulargood in an associated relationship; and wherein the entire outer surfacerepresented by a plurality of recordings, and the entire inner surfacerepresented by a plurality of different recordings are then furtherassociated in three-dimensional space by measuring: the relativeposition and distance of the outer surface geometric center point of theinitial longitudinal section from the inner surface geometric centerpoint of the initial longitudinal section, and the relative position anddistance of the outer surface geometric center point of the lastlongitudinal section from the inner surface geometric center point ofthe last longitudinal section.

Example 22

The method of Example 21, wherein the selected section includes outerand inner diameters of the entire tubular surface and associated withthe geometric centers throughout the entire longitude of the tubulargood and further associated with: the relative position of the initiallongitudinal section's outer surface center point with respect to theinitial section's inner surface center point, and the relative positionof the last longitudinal section's outer surface center point withrespect to the last section's inner surface center point.

Example 23

The method of one or more of Examples 21-22, wherein the spacing of thediscrete portions within the section of the outer and inner surfaces ofthe tubular good is such that each determination of outer and innerdiameters of each adjacent discrete portion of the section of the outerand inner surface of the tubular is appropriate for the resolutiondesired, and wherein one geometric center is determined for eachlongitudinal discrete portion.

Example 24

The method of one or more of Examples 21-23, wherein the number of thediscrete portions within the section of the outer and inner surfaces ofthe tubular good are spaced around the circumference of the tubular toestablish the determined resolution.

Example 25

The method of one or more of Examples 21-24, further including the stepof causing a digital computer means to use at least some of theinformation which has been recorded in a digital, computer readableformat to compute the effect of stressors on the calculated wall of thetubular good.

Example 26

The method of one or more of Examples 21-25, further comprising the stepof causing a digital computer means to use at least some of theinformation which has been recorded in a digital, computer readablerecording to display outer diameters and inner diameters in associationwith the single geometric center point of each discreet longitudinalsection of the tubular good to construct a true virtualthree-dimensional form of the full length of the tubular good.

Although the various embodiments of the devices have been describedherein in connection with certain disclosed embodiments, manymodifications and variations to those embodiments may be implemented.Also, where materials are disclosed for certain components, othermaterials may be used. Furthermore, according to various embodiments, asingle component may be replaced by multiple components, and multiplecomponents may be replaced by a single component, to perform a givenfunction or functions. The foregoing description and the followingExamples are intended to cover all such modification and variations.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples.

Any patent, publication, or other disclosure material, in whole or inpart, that is to be incorporated by reference herein is incorporatedherein only to the extent that the incorporated material does notconflict with existing definitions, statements, or other disclosurematerial set forth in this disclosure. As such, and to the extentnecessary, the disclosure as explicitly set forth herein supersedes anyconflicting material incorporated herein by reference. Any material, orportion thereof, that to be incorporated by reference herein, but whichconflicts with existing definitions, statements, or other disclosurematerial set forth herein will only be incorporated to the extent thatno conflict arises between that incorporated material and the existingdisclosure material.

What is claimed is:
 1. A method of inspecting a tubular good, the methodcomprising: selecting a cross-section of the tubular good that istransverse to a longitudinal axis extending through the tubular good;longitudinally positioning at least one measuring apparatus at aposition with respect to the cross-section; while the measuringapparatus is at the position, determining the longitudinal position ofthe measuring apparatus along the longitudinal axis of the tubular good;while the measuring apparatus is at the position, determining thecircumferential position of the measuring apparatus about acircumference of the cross-section; selecting diametric sections indiscrete positions around the circumference of the cross-section of thetubular good; measuring an outside diameter and inside diameter at eachof the diametric sections around the circumference of the cross-sectionvia the at least one measuring device; determining a geometric center ofthe cross-section; and repeating the above-listed steps at a pluralityof other sections of the tubular good that are orthogonal to thelongitudinal axis.
 2. The method of claim 1, wherein the measuringdevice comprises a laser measuring device.
 3. The method of claim 1,wherein the measuring device comprises a light measuring device.
 4. Themethod of claim 1, further comprising the step of storing digitalrecordings of the outer diameters, the inner diameters, and thegeometric center of the cross-section.
 5. The method of claim 4, whereinthe digital recordings comprise: first digital recordings configured todefine an outer surface of the tubular good; and second digitalrecordings configured to define an inner surface of the tubular good. 6.The method of claim 5, further comprising the step of associating theouter surface and the inner surface of the tubular good to calculate awall of the tubular good in three dimensional space.
 7. The method ofclaim 6, further comprising the steps of: measuring the relativeposition and distance of an outer surface geometric center point of aninitial section from an inner surface geometric center point of theinitial section; and measuring the relative position and distance of anouter surface geometric center point of a last section from the innersurface geometric center point of the last section.
 8. The method ofclaim 7, further comprising the step using at least some of the digitalrecordings to compute the effect of stressors on the calculated wall ofthe tubular good.
 9. The method of claim 8, further comprising the stepof using at least some of the digital recordings to construct a virtualthree-dimensional form of the tubular good.
 10. The method of claim 1,wherein the discrete positions of the diametric sections are equallyspaced around the circumference.
 11. A system of inspecting a tubulargood, the system comprising: an outer unit comprising at least one outermeasuring device; an inner unit comprising at least one inner measuringdevice; and a control circuit coupled to the outer unit and the innerunit, wherein the control circuit is configured to perform the steps of:selecting a cross-section of the tubular good that transects alongitudinal axis extending through the tubular good; longitudinallypositioning the outer unit at a first position outside thecross-section; while the outer unit is at the first position,determining the longitudinal position of the outer unit along thelongitudinal axis of the tubular good; while the outer unit is at thefirst position, determining the circumferential position of the outerunit about a circumference of the cross-section; longitudinallypositioning the inner unit at a second position inside thecross-section; while the inner unit is at the second position,determining the longitudinal position of the inner unit along thelongitudinal axis of the tubular good; while the inner unit is at thesecond position, determining the circumferential position of the innerunit about the circumference of the cross-section; selecting diametricsections in discrete positions around the circumference of thecross-section of the tubular good; measuring an outside diameter andinside diameter at each of the diametric sections around thecircumference of the cross-section via the at least one measuringdevice; determining a geometric center of the cross-section; andrepeating the above-listed steps at a plurality of other sections of thetubular good that are orthogonal to the longitudinal axis.
 12. Thesystem of claim 11, wherein the outer unit comprises a laser measuringdevice.
 13. The system of claim 12, wherein the inner unit comprises alaser measuring device.
 14. The system of claim 11, wherein the outerunit comprises a light measuring device.
 15. The system of claim 14,wherein the inner unit comprises a light measuring device.
 16. Thesystem of claim 11, wherein the control circuit comprises a memory, andwherein the control circuit is configured to store digital recordings ofthe outer diameters, the inner diameters, and the geometric center ofthe cross-section in the memory.
 17. The method of claim 16, wherein thedigital recordings comprise: first digital recordings configured todefine an outer surface of the tubular good; and second digitalrecordings configured to define an inner surface of the tubular good.18. The system of claim 17, further comprising the step of associatingthe outer surface and the inner surface of the tubular good to calculatea wall of the tubular good in three dimensional space.
 19. The system ofclaim 18, further comprising a middle unit, wherein the control circuitutilizes the middle unit to perform the steps of: measuring the relativeposition and distance of an outer surface geometric center point of aninitial section from an inner surface geometric center point of theinitial section; and measuring the relative position and distance of anouter surface geometric center point of a last section from the innersurface geometric center point of the last section.
 20. The system ofclaim 19, wherein the control circuit is configured to construct avirtual three-dimensional form of the tubular good using at least someof the digital recordings stored in the memory.
 21. A method forcollection and storage of information representing the outer and innerdiameters of a tubular surface, and the associated geometrical centersof the longitudinal section which represent the three-dimensionallongitudinal or helical straightness of tubular goods, the methodcomprising: (a) selecting a diametric section of the circumference ofthe tubular good about which information representing the outerdiameter, inner diameter and geometric center of the longitudinalsection is to be recorded in a format readable by digital computermeans; (b) determining number and spacing of diametric sections indiscrete positions around the circumference of a longitudinal section ofthe tubular good which will produce information representingcircumferential outside and inside diameters of the tubular good havinga determined resolution and a geometrical center representing theassociated longitudinal section; (c) longitudinally positioning a laseror light measuring apparatus which is capable of measuring the outsidediameter and inside diameter at a desired number of adjacent positionsaround the circumference and measuring the geometric center of eachassociated longitudinal section of the tubular good in a plurality ofadjacent positions in an area of the tubular good to be inspected; (d)while the laser or light measuring apparatus is at the position,determining the longitudinal position of the laser or light measuringapparatus along the axis of the tubular good; (e) while the laser orlight measuring apparatus is at the position, determining thecircumferential position of the laser or light measuring apparatus aboutthe circumference of the tubular good; (f) while the laser or lightmeasuring apparatus is at the position, causing the laser or lightmeasuring apparatus to determine the outer and inner diameters, andgeometric center of a discrete longitudinal section of the tubular goodto which the laser or light measuring apparatus is proximate; (g) makinga digital recording of outer and inner diameters, geometric center ofthe section, the longitudinal position, and the circumferential positionin an associated relationship; (h) repeating steps (c) through (g) aboveat a plurality of other circumferential and longitudinal positions ofthe selected section which have not been previously determined andrecorded, until all of the outside and inside diameters representing thedetermined resolution of the selected section has been determined andrecorded, and is represented by a plurality of recordings, each of whichrepresents outer and inner diameter, the outer and inner geometriccenters of the section, longitudinal position and circumferentialposition of a discrete portion of the calculated wall of the tubulargood in an associated relationship; and wherein the entire outer surfacerepresented by a plurality of recordings, and the entire inner surfacerepresented by a plurality of different recordings are then furtherassociated in three-dimensional space by measuring: the relativeposition and distance of the outer surface geometric center point of theinitial longitudinal section from the inner surface geometric centerpoint of the initial longitudinal section, and the relative position anddistance of the outer surface geometric center point of the lastlongitudinal section from the inner surface geometric center point ofthe last longitudinal section.
 22. The method of claim 21, wherein theselected section includes outer and inner diameters of the entiretubular surface and associated with the geometrical centers throughoutthe entire longitude of the tubular good and further associated with:the relative position of the initial longitudinal section's outersurface center point with respect to the initial section's inner surfacecenter point, and the relative position of the last longitudinalsection's outer surface center point with respect to the last section'sinner surface center point.
 23. The method of claim 22, wherein thespacing of the discrete portions within the section of the outer andinner surfaces of the tubular good is such that each determination ofouter and inner diameters of each adjacent discrete portion of thesection of the outer and inner surface of the tubular is appropriate forthe resolution desired, and wherein one geometric center is determinedfor each longitudinal discrete portion.
 24. The method of claim 23,wherein the number of the discrete portions within the section of theouter and inner surfaces of the tubular good are spaced around thecircumference of the tubular to establish the determined resolution. 25.The method of claim 24, further including the step of causing a digitalcomputer means to use at least some of the information which has beenrecorded in a digital, computer readable format to compute the effect ofstressors on the calculated wall of the tubular good.
 26. The method ofclaim 23, further comprising the step of causing a digital computermeans to use at least some of the information which has been recorded ina digital, computer readable recording to display outer diameters andinner diameters in association with the single geometric center point ofeach discreet longitudinal section of the tubular good to construct atrue virtual three-dimensional form of the full length of the tubulargood.